Coil unit



4- G. v. CRADDOCK ET AL 2,339,054

COIL UNIT Filed April 5, 1941 4 k if x F I 6 I INVENTORS 6. M CRADDOCK E.'. FRA NZ Patented Jan. 11, 1944 con. UNIT Gerald V. Craddock, New York, N. Y., and Erwin E. Frans. Cranford, N. 1., assignors to Western Electric Company, Incorporated, New York, N. Y., a corporation of New York Application April 5, 1941, Serial No. 387,018

6 Claims.

This invention relates to coil units, and more particularly to electrical coil units of the communication arts.

An object of the invention is to provide a simple, efflclent and highly practical electrical coil unit.

With this and other objects in view, the invention comprises an electrical coil unit having a head formed to receive a core portion upon which a coil may be disposed or wound and to which another core portion may be subsequently secured, the head being molded with a selected number of like terminals to receive leads from the coil and including a material that may be fused with a covering for the coil. Other objects and advantages will be apparent from the following detailed description when taken in conjunction with the accompanying drawing, wherein Fig. 1 is a vertical sectional view of an electrical coil unit embodying the invention;

Fig. 2 is a vertical sectional view taken substantially along the line 22 of Fig. 1;

Fig. 3 is an enlarged fragmentary sectional view taken substantially along the line 33 of F18. 1, and

Fig. 4 is a fragmentary elevational view taken along the line 4-4 of Fig. 3.

Referring now to the drawing, the electrical coil unit illustrating the invention comprises a head indicated generally at ID, of the contour illustrated, and molded mainly of a phenol plastic material excepting a lower portion indicated at II, this portion being composed of a suitable soluble insulating material which in the'present instance is cellulose acetate. The head It consists mainly of a vertical portion I 2 and a horizontal portion 13, the latter being apertured at I4 to receive a core member it. The core member i5 is composed of a stack of L-shaped laminations inverted as illustrated in Figs. 2 and 3 so that the vertical portion thereof will extend through the aperture l4, while the horizontal portion rests upon the upper surface of the portion I! of the head. Upon this core member I! a coil i8 may be disposed or wound, the coil having leads l9 extending therefrom. A covering 20 is disposed about the coil, this cover being formed of a soluble material such as cellulose acetate and extending to the ends of the coil whereby the upper end may coalesce with the material ll through the aid of a suitable solvent such as acetone.

Referring again to the head, attention is directed to an outwardly projecting portion 24 which has a plurality of spaced recesses 28 formed therein with diagonally extending inner walls 21 projecting outwardly and upwardly from the top of the coil It. A desired number of like terminals 30 are molded in the head I 0' at selected recesses 26. For illustration, attention is directed to Fig. 4, wherein two terminals are shown as being molded in the head adjacent the .second and fourth recesses, reading from the left. In molding the terminals in the head they are positioned adjacent one wall of their respective recesses, leaving an open top portion of these recesses for the passage of the leads I! in securing the latter to the terminals.

The terminals 30 are of the flat strip type and of the contour illustrated in Fig. 3. By viewing this figure, it will be observed that the terminal shown therein has an-aperture 3i to receive material of the head, during the molding process of the latter, to serve in anchoring the terminal in the head. The portion of the terminal adjacent the aperture 3l is enlarged, projecting inwardly, that is to the right, providing a surface 32 which is flush with the inner wall of the vertical portion l2. Beneath this portion of the terminal, the material of the terminal extends inwardly and downwardly to a projection 33 which forms another anchoring portion to anchor the terminal in the head. Projecting from the head is a triangular portion 34 providing a diagonally extending surface 35 which cooperates with the adjacent surface of the head in forming a V- shaped recess for wedgingly receiving one of the leads IS. The portion 34 also provides a surface 36 extending diagonally downwardly to maintain the lead against displacement when wound on the portion 34 and cause the lead to lie adjacent the head. Above the head I 0 and at the upper end of the enlarged portion of the terminal a notch 31 is formed in the terminal to receive a loop formed of one of the leads l9. At this point in the formation of the coil unit, the leads from the coil are drawn upwardly through the desired recesses 26, at which time any insulationon the leads is removed and the ibare conductor wires of the leads are drawn through their respective recesses and bent inwardly so that they will lie in notches or recesses 38 in the upper edge of the head III, as illustrated in Figs. 3 and 4. The notches 38 are so formed and positioned with respect to their terminals that the vertical portions of the leads extending from the coil to the notches are spaced from their terminals as clearly shown in Fig. 4. The leads are then passed around their ter-.

of the head to wedgingly receive the leads. The

leads are thus held in place with a looped portion about the terminal and as soon as each winding operation is completed the operator may break the remaining portions of the leads, the break occurring at the farthest edge of the surfaces 35, this edge serving as a shearing means for the leads. The leads having been secured to their respective terminals, the structure thus far assembled may be inverted to lower the terininals into molten solder to a point adjacent the head to solder the leads to their terminals.

In continuing with the structure of the coil unit, attention is directed to Fig. 2, which shows an insulating washer 39 disposed adjacent the lower end of the coil and apertured toreceive the core'member I5. Another core member 40 composed of a group of laminations identical to the group composing the core member l5, may be disposed in reverse order and joined at their lower extremities by connecting plates 4i through the aid of bolts 42, the latter extending through apertures in the core members. At their upper ends the. core members are joined through the aid of a plate 43 and bolts 44 in addition to a mounting bracket 45, the latter being T-shaped in cross section with the vertical leg thereof apertured to receive the bolts. The bolts 44 extend through apertures in the plate 43 and the core members l5 and 40. The horizontal or top portion of the mounting bracket 45 is provided with threaded apertures 46 for mounting upon a suitable support such as a frame (not shown).

This entire structureis disposed in a casing 46 lined with a suitable insulating material 41 and secured to the assembly by integral tabs 48 bent inwardly, as shown in Figs. 1 and 2, against the upper surface of the mounting bracket 45.

In reviewing the coil unit structure, it will be observed that the head is molded of a durable material and formed to receive a coreportion,

notches 33 relative to the terminals is important in that these notches cause the upwardly extending legs of the loops or leads to be spaced from the terminals so that they will not be disturbed and suffer possible breakage during the winding of the leads on the portion 34.

, The embodiment of the invention herein disclosed is merely illustrative and may be modified and departed from in many ways without departing from the spirit and scope of the invention as pointed out in and limited only by the appended claims.

, What is claimed is:

l. A terminal structure for a coil unit including acoil having a lead, the terminal structure comprising a. body molded of insulating material, and a fiat plate type terminal having a plurality of portions, one molded in the body and disposed at right angles with respect to an adjacent surface thereof, another having a notch to receive a looped portion of the lead and still another having a surface extending diagonally from the said surface of the body and cooperating therewith to form a groove to'wedgingl'y receive an end portion of the lead to hold the looped portion thereof in the notch.

2. A terminal structure for a coil unit including a coil having a lead, the terminal structure comprising a body molded of insulating material, and a flat plate type terminal having a plurality of portions, one molded in the body and disposed at right angles with respect to an adjacent surface thereof, another having a notch to receive a looped portion of the lead and a shoulder projecting beyond the notch to assist in locating the lead in the notch, and still another portion having a surface extending diagonally from the said surface of the body and cooperating therewith to form a groove to wedgingly receive an end portion of the lead to hold the looped portion thereof in the notch.

3. A terminal structure for a coil unit including a coil having a lead, the terminal structure and also provided with a soluble material to be joined through coalescence witha cover of a coil, wound upon the core, to form a rigid unit including the head, the core and the coil. This rigid unit is maintained also by the molding of the like terminals in the head, any desired number of terminals being employed and disposed at selected positions relative to recesses through which the leads of the coil may extend and be separated one from another. Through the construction of the terminal and head assembly, the leads may be readily formed in loops about their respective terminals, the enlarged portions of the terminals beneath the notches 3'! serving as shoulders upon which the ends of the loops may drop to enter the notches during their formation. Furthermore, the fastening of the leads so that the positions of their loops in the notches may be maintained is simplified by the provision of the portion 34 and the diagonal surfaces 35 and 33 forthe free wrapping of the leads thereabout and the severing of the excess portions of the leads adjacent the surface 35. The location of the .comprisinga body molded of insulating material,

and a flat plate type terminal having a plurality of portions, one molded in the body and disposed at right angles with respect to an adjacent flat surface thereof, another having a notch to receive a looped portion of the lead and still another portion having opposing diagonal surfaces about which the lead from the notch may be wound, one of the surfaces cooperating with the said flat surface of the body in forming a recess for wedgingly holding the lead while the other surface holds the wound portion of the lead against displacement.

4. A terminal structure for a. coil unit including a coil having a lead and a cover portion formed of a soluble material, the terminal structure comprising a body of a non-soluble insulating material and a soluble insulating material made integral by molding, the soluble material being disposed adjacent the coil, soluble with the material of the said cover portion and thus joined thereto, and a terminal having ananchoring portion molded in the body and another portion projecting from the body with a surface extending diagonally from a surface of the body, the surfaces cooperating to form a groove to wedgingly receive the lead.

5. A terminal structure for a coil unit including a coil having a lead and a cover portion an end portion of the lead to hold the looped portion thereoi in the notch.

6. A terminal structure for a coil unit including a coil having a lead, the terminal structure comprising a body molded of insulating material with a lead receiving groove therein, and a flat plate type terminal disposed a predetermined distance irom the groove and having a plurality of portions, one molded in the body and disposed at right angles with respect to an adjacent flat surface thereof, another having a notch to receive the lead from the said groove, and still another portion having a surface extending diagonally from the said flat surface of the body and cooperating therewith in forming a recess for wedgingly holding the lead extending from the notch.

GERALD V. CRADDOCK.

ERWIN E. FRANZ. 

